Customized Non-standard Gearbox Plastic Machinery Rubber Extruder Gearbox Reducer

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Product Description

Key Features

High torque and power density: They are compact yet capable of transmitting extremely high torque. This is crucial for rotating the extruder screw when processing high-viscosity polymers. Integrated high-capacity thrust bearing: Arguably the most critical feature, the gearbox must absorb the enormous axial thrust (back pressure) generated by the extruder screw as it pushes the molten plastic into the die. These gearboxes utilize robust thrust bearing assemblies (typically spherical or cylindrical roller thrust bearings) to ensure trouble-free handling of these loads. Durable and precise gearing: Gears: These typically utilize hardened, ground helical and bevel gears made of high-grade alloy steel (such as 20CrMnTi). This design ensures smooth, quiet operation, high efficiency, and a long service life under sustained heavy loads. High precision: Gears are manufactured to high-precision standards (e.g., DIN 6 or higher) to minimize noise, vibration, and wear. Rugged Housing: Gearbox housings are typically constructed of high-strength cast iron or structural steel. Their design provides high rigidity, maintains precise gear alignment under high torque and thrust loads, and aids in heat dissipation. Advanced Cooling and Lubrication Systems: Continuous high-torque operation generates significant heat. These gearboxes are equipped with specialized lubrication and cooling systems, which may include: Splash or forced lubrication: Ensures that all gears and bearings are lubricated at all times. Internal Cooling Coil: A water-cooling circuit within the oil sump helps regulate temperature. External Heat Exchanger: Large units often use an external oil cooler (air or water) with a pump for optimal thermal stability. Low Noise and Vibration: Precision-ground helical gears and a rugged housing help reduce operating noise, which is critical for workplace safety and environmental standards. Application-Specific Design: Gearboxes are not one-size-fits-all. They are specifically designed for different types of machinery, such as single-screw or twin-screw extruders.

Application

Single-screw extruders: This is the most common application. Gearboxes provide the torque to rotate the single screw used to produce pipe, profiles, sheet, film, and cable. Twin-screw extruders (co-rotating and counter-rotating): These extruders require more complex gearboxes to not only reduce torque but also distribute the input power to drive the two intermeshing screws. Gearboxes are essential for compounding, mixing, and specialty extrusion processes that require high mixing efficiency. Injection molding machines: Gearboxes drive the screws that plasticize (melt) the polymer and inject it into the mold. They must handle the cyclic loads of the injection molding process. Blow molding machines: Gearboxes drive the extruder screws, which inflate the "parison" (a tube of molten plastic) into the final shape, such as a bottle or container. Plastic recycling machinery: Gearboxes are key components of shredders, pelletizers, and recycling extruders, providing the high torque required to break down and reprocess plastic waste. Blown Film and Cast Film Lines: The extruder portion of these lines relies on a robust gearbox to produce a consistent and uniform melt, resulting in high-quality film.

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